Simulation of powder bed metal additive manufacturing microstructures with coupled finite difference-Monte Carlo method

Rodgers, Theron M.; Moser, Daniel; Abdeljawad, Fadi; Jackson, Olivia D. Underwood; Carroll, Jay D.; Jared, Bradley H.; Bolintineanu, Dan S.; Mitchell, John A.; Madison, Jonathan D.

doi:10.1016/j.addma.2021.101953

Simulation of powder bed metal additive manufacturing microstructures with coupled finite difference-Monte Carlo method

Journal Article · 22 March 2021 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2021.101953· OSTI ID:1773924

Rodgers, Theron M. ^[1]; Moser, Daniel ^[1]; Abdeljawad, Fadi ^[2]; Jackson, Olivia D. Underwood ^[1]; Carroll, Jay D. ^[1]; Jared, Bradley H. ^[3]; Bolintineanu, Dan S. ^[1]; Mitchell, John A. ^[1]; Madison, Jonathan D. ^[1]

Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Clemson Univ., SC (United States)
Univ. of Tennessee, Knoxville, TN (United States)

Grain-scale microstructure evolution during additive manufacturing is a complex physical process. As with traditional solidification methods of material processing (e.g. casting and welding), microstructural properties are highly dependent on the solidification conditions involved. Additive manufacturing processes however, incorporate additional complexity such as remelting, and solid-state evolution caused by subsequent heat source passes and by holding the entire build at moderately high temperatures during a build. We present a three-dimensional model that simulates both solidification and solid-state evolution phenomena using stochastic Monte Carlo and Potts Monte Carlo methods. The model also incorporates a finite-difference based thermal conduction solver to create a fully integrated microstructural prediction tool. The three modeling methods and their coupling are described and demonstrated for a model study of laser powder-bed fusion of 300-series stainless steel. The investigation demonstrates a novel correlation between the mean number of remelting cycles experienced during a build, and the resulting columnar grain sizes.

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Research Organization:: Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC04-94AL85000; NA0003525

OSTI ID:: 1773924

Alternate ID(s):: OSTI ID: 1773289

Report Number(s):: SAND-2021-3493J; 695011

Journal Information:: Additive Manufacturing, Vol. 41; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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